Exterior rearview mirror assembly

ABSTRACT

An exterior rearview mirror assembly for a vehicle includes a bracket fixedly secured to the vehicle, a mirror casing secured to the bracket and defining a primary opening, and a primary mirror disposed within said primary opening for providing a view rearward of the motor vehicle through a primary field of view. The primary mirror defines a primary plane. A spotting mirror is spaced apart from the primary mirror and extends through a secondary plane different from the primary plane. A divider extends between the primary mirror and the spotting mirror to separate the primary and secondary mirrors visually

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a division of U.S. patent application Ser.No. 13/336,018, filed Dec. 23, 2011 (Attorney Docket DON09 P-1800),which is a continuation of U.S. patent application Ser. No. 12/911,274,filed Oct. 25, 2010, now U.S. Pat. No. 8,128,243, which is acontinuation of U.S. patent application Ser. No. 12/851,045, filed Aug.5, 2010, now U.S. Pat. No. 7,934,843, which is a continuation of U.S.patent application Ser. No. 12/197,666, filed Aug. 25, 2008, now U.S.Pat. No. 7,842,154, which is a division of U.S. patent application Ser.No. 10/709,434, filed May 5, 2004, now U.S. Pat. No. 7,420,756, whichclaims the benefit of U.S. provisional application Ser. No. 60/471,872,filed May 20, 2003, which are hereby incorporated herein by reference intheir entireties.

FIELD OF THE INVENTION

The present invention relates generally to rearview minor elements for arearview mirror assembly of a vehicle and, more particularly, toexterior rearview mirror elements comprising multi-radius reflectiveelements.

BACKGROUND OF THE INVENTION

Typically, minor reflective elements are formed of glass and have areflective coating deposited thereon, such as via vacuum deposition orwet chemical silvering or the like, such as on a silver line, such asdescribed in U.S. Pat. No. 4,737,188, which is hereby incorporatedherein by reference. Polymeric reflective elements are also known, suchas are described in U.S. Pat. Nos. 6,601,960; 6,409,354; 4,944,581;4,385,804; 4,193,668; 4,666,264; and 5,483,386, which are herebyincorporated herein by reference. For such polymeric mirror reflectiveelements, the need exists for a hard coat or surface on the first orouter or exterior surface of the element which is contacted by theexterior elements, such as rain, road debris, or the like, or contacted,for example, by a person scraping ice or wiping snow or condensation offthe mirror element outer surface, such as during winter. A variety ofhard coats have been proposed in the art, typically applied by dipcoating or vacuum deposition techniques. However, a need exists for anautomotive mirror reflective element which has the properties of plastic(i.e., a specific gravity roughly half that of glass), and which has aglass-like exterior surface.

Also, exterior rearview minor reflective elements may be aspheric ormulti-radius, and may typically have a less curved or substantially flat(around 2000 mm radius or thereabouts) inboard portion or surface at theinboard side of the reflective element (i.e., closer to the side body ofthe vehicle when the minor assembly is mounted to the vehicle), and amore curved multi-radius portion or surface at the outboard side of thereflective element (i.e., further from the side body of the vehicle whenthe mirror assembly is mounted to the vehicle), in order to provide anextended field of view. It is typically desirable to have the reflectiveelements or substrates of such exterior minor elements to be formed of aglass material because glass material typically provides an enhancedscratch resistance over conventional optical resins and the like.

Therefore, there is a need in the art for a mirror reflective elementthat overcomes the shortcomings of the prior art elements andsubstrates.

SUMMARY OF THE INVENTION

The present invention provides a molded wide angle or multi-radiussubstrate for a reflective element. The molded substrate comprises apolymeric optical resin transparent material and has a curved exteriorsurface, which may have a less curved/flatter or substantially flatinboard portion or surface and a more curved outboard portion orsurface. The molded substrate may have an anti-abrasion film or layer,such as an ultrathin glass film, applied over the exterior surface orfirst surface to provide substantial protection against scratchesoccurring to the molded substrate. The inner surface or second surfaceof the reflective element substrate may have a reflective coating orlayer, such as a polymeric reflective film, laminated or adhered orotherwise applied thereto.

According to an aspect of the present invention, a wide angle reflectiveelement for a mirror assembly for a vehicle includes a wide anglesubstrate having an exterior surface and a glass film disposed at theexterior surface. The exterior surface of the substrate has a lesscurved inboard portion or surface and a more curved outboard portion orsurface. The substrate comprises a polymeric resin material. The glassfilm is adapted to substantially conform to the exterior surface of thewide angle substrate. The glass film comprises a glass material and hasa thickness of less than approximately 0.8 mm.

According to another aspect of the present invention, a reflectiveelement for a mirror assembly for a vehicle comprises a substrate havingan exterior surface, and an anti-abrasion film applied to the exteriorsurface. The substrate comprises a polymeric resin material, such as atransparent optical polymeric resin material. The anti-abrasion filmpreferably comprises a glass material (such as a soda lime glass or aborosilicate or the like) and has a thickness of less than approximately0.8 mm, and is flexible to conform to the exterior surface.

The substrate may be cut from a strip or sheet of molded or extruded orcast substrate material (or less preferably, may be cut from an injectedmolded strip or sheet). The flexible glass film may be unrolled from areel or roll and applied to the exterior surface of the elongated stripor sheet of substrate material. The substrate, including the glass filmor layer, may then be cut or otherwise formed from the elongated stripor sheet.

The substrate may comprise a wide angle substrate and/or may comprise amulti-radius exterior surface having a less curved inboard portion orsurface and a more curved outboard portion or surface.

A reflective film or layer may be applied to the inner surface or sideof the substrate or strip opposite the exterior surface. The reflectivefilm may comprise a polymeric reflective film laminated or otherwiseadhered or applied to the inner side of the substrate or strip. Thereflective film may comprise an all polymer-thin-film multilayer, highreflective mirror film comprising multiple coextrusion of many plasticlayers to form a highly reflective mirror film.

Optionally, a reflective film or layer may be applied to the exteriorsurface of the substrate or sheet or strip, and the glass film or layeror sheet may be applied over the reflective film layer. In such anapplication, the substrate acts as a support or backing plate for thereflective film or layer and the glass film or layer, whereby opticalclarity/transparency of the substrate material is not necessary.

According to another aspect of the present invention, a method forforming a reflective element substrate for a mirror assembly of avehicle comprises generally continuously forming an elongated strip orsheet of substrate material and applying a substantially transparentfunctional film, such as an anti-abrasion film or a hydrophilic film ora hydrophobic film or the like, to a surface of the elongated stripsheet. The substrate material may comprise a transparent opticalpolymeric resin. The functional film is preferably unrolled from a reelor roll of film and applied to the surface of the elongated strip orsheet generally continuously as the strip or sheet is formed or extrudedor cast or molded. Preferably, multiple minor element shapes or minorelement substrates may be cut or otherwise formed from the elongatedsheet after the functional film is applied to the surface of the stripor sheet.

The functional or anti-abrasion film may comprise an ultrathin glassmaterial which is sufficiently flexible to be provided in a reel or roll(or in a sheet that is flexible and conformable to a bent substrate).The substrates may be formed with a wide angle exterior surface or amulti-radius exterior surface. The anti-abrasion film may besufficiently flexible to conform to the wide angle or multi-radius orcurved exterior surface.

A reflective film, such as a polymeric reflective film or the like, maybe applied to the opposite surface of the substrate or sheet or strip.The reflective film may be sufficiently flexible to be provided in areel or roll form (or in a sheet that is flexible and conformable to abent substrate) for unrolling the reflective film as the film isgenerally continuously applied to the surface of the generallycontinuously formed sheet or strip.

Therefore, the present invention provides a molded wide angle ormulti-radius single substrate for a rearview minor assembly which has ananti-abrasion or anti-scratch film or layer applied to the curved, wideangle or multi-radius exterior surface of the substrate. Theanti-abrasion film preferably comprises an ultrathin glass film or sheetto provide enhanced scratch resistance. The molded substrate may have areflective film or layer laminated or applied to the inner surfaceopposite the exterior surface.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exterior rearview mirror assembly inaccordance with the present invention;

FIG. 2 is a perspective view of a wide angle or multi-radius reflectiveelement in accordance with the present invention;

FIG. 3 is a sectional view of the wide angle or multi-radius reflectiveelement taken along the line III-III in FIG. 2;

FIG. 4 is a sectional view similar to FIG. 3, showing a wide angle ormulti-radius reflective element in accordance with the present inventionwith a reflective film or layer applied to the exterior surface of theelement and an anti-abrasion film or layer applied over the reflectivefilm or layer;

FIG. 5 is a diagram showing the extruding, coating and cutting processesfor manufacturing a prismatic minor reflective element in accordancewith the present invention;

FIG. 5A is an elevation of the extruder of FIG. 5, showing the wedgeshape of the extruded strip and reflective element substrate;

FIG. 6 is a plan view of the extruded strip showing the cut out shapesof the reflective element cut from the extruded strip;

FIG. 7 is a sectional view of the reflective element formed by theprocess shown in FIG. 5;

FIG. 8 is a diagram showing an alternate process for manufacturing aprismatic minor reflective element in accordance with the presentinvention, where a strip of substrate material is cast and formed via acaster and float section;

FIG. 9 is a perspective view of an automobile equipped with exteriorsideview mirror assemblies according to this present invention;

FIG. 10 is a top plan partial fragmentary view of the driver's sideexterior rearview mirror assembly of FIG. 9;

FIG. 11 is an enlarged sectional view of a plano-multiradius reflectiveelement assembly of the mirror assembly in FIG. 10;

FIG. 12 is an enlarged sectional view of a demarcation element of theplano-multiradius reflective element assembly of FIG. 11;

FIGS. 13A-13H illustrate views of various locations for a planoreflective element and an auxiliary reflective element according to thispresent invention;

FIG. 14 is a sectional view of a second embodiment of a plano reflectiveelement assembly according to the present invention including ademarcation element formed as a dividing wall in a backing plateelement;

FIG. 14A is a cross-section taken along line XX of FIG. 14;

FIG. 14B is a cross-sectional view taken along line YY of FIG. 14;

FIG. 15 is a schematic of a third embodiment of a plano-auxiliaryreflective element assembly according to this present invention;

FIG. 16 is a front elevation view of another embodiment of a planoreflective element assembly according to the present invention;

FIG. 17 is an exploded perspective view of the plano reflective elementassembly of FIG. 16;

FIG. 18 is an end view of the plano reflective element assembly of FIG.16 as viewed from line XVIII-XVIII of FIG. 16;

FIG. 19 is a top view of the plano reflective element assembly of FIG.16 as viewed from line XIX-XIX of FIG. 16;

FIG. 20 is a schematic representation of the plano reflective elementassembly of FIG. 16 illustrating the orientation of the reflectiveelement;

FIG. 21 is another schematic representation of the orientation of thereflective elements of the plano reflective element in FIG. 16;

FIG. 22 is a diagram illustrating the range of viewing of the reflectiveelements of the plano reflective element assembly of FIG. 16; and

FIG. 23 is a perspective view of another embodiment of an exteriorrearview minor system of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depictedtherein, an exterior rearview minor assembly 10 includes a reflectiveelement 12 mounted at a casing 14, which is mounted at an exteriorportion of a vehicle 16 (FIG. 1). Reflective element 12 may provide anenhanced field of view or wide angle field of view to a driver oroccupant of the vehicle and may comprise a single reflective elementsubstrate 18 having an inner surface 18 a and an opposite exteriorsurface 18 b (FIGS. 2 and 3). The exterior surface 18 b comprises a lesscurved or substantially flat inboard portion or surface 18 c and a morecurved outboard portion or surface 18 d, as discussed below. Thesubstrate 18 may have an anti-abrasion coating or layer or film 20, suchas an ultrathin glass coating or layer or film, laminated or depositedor otherwise applied to the exterior surface 18 b, and may have areflective coating or layer 22 laminated or applied to the inner surface18 a, as also discussed below. Aspects of the reflective element of thepresent invention may be suitable for use in a reflective element for anexterior rearview mirror assembly (as shown in FIG. 1) and/or areflective element for an interior rearview mirror assembly (not shown).

Reflective element 12 may comprise an aspheric or multi-radius or wideangle single element reflective element substrate. The reflectiveelement 12 may provide a field of view similar to the plano-auxiliaryreflective element assembly disclosed in U.S. Pat. Nos. 6,522,451 and6,717,712, which are hereby incorporated herein by reference.

As illustrated in FIG. 9 from U.S. Pat. No. 6,717,712, incorporatedabove, passenger automobile 110 (which may be a sedan, a station-wagon,a sports car, a convertible, a minivan, a sports utility vehicle, apick-up truck or a similar passenger carrying non-commercial, personaltransportation automobile) includes an interior rearview minor assembly127 positioned within interior vehicle cabin 125. Interior vehicle cabin125 further includes a steering wheel 116, a driver seat 129 positionedat steering wheel 116, a front passenger seat 121 adjacent to driverseat 129 in the front portion of cabin 125, and a rear passenger seat123 in the rear portion of cabin 125. Automobile 110 further includes adriver-side exterior sideview minor assembly 112 and a passenger-sideexterior sideview mirror assembly 114, each adapted for attachment toopposing sides of automobile body 111, most preferably adjacent to theseating position of the driver seated in driver seat 129 for driver-sideassembly 112 and adjacent to the front passenger seat 121 forpassenger-side assembly 114. Exterior sideview mirrors, mounted as shownin FIG. 9 close to the driver seating location, are commonly referred toas door-mounted exterior sideview minor assemblies. Driver-side exteriorsideview mirror assembly 112 includes, as illustrated in FIG. 10, aplano-multiradius exterior sideview reflective element assembly 130.Plano-multiradius reflective element assembly 130 is mounted to areflective element positioning actuator 136. The orientation ofplano-multiradius reflective element assembly 130, and hence itsrearward field of view, is adjustable by actuator 136 in response tocontrol 137. Control 137 can comprise a handset control that allows thedriver manually move the orientation of plano-multiradius reflectiveelement assembly 130 within exterior minor housing 140 (such as by alever control or by a cable control) and hence reposition the rearwardfield of view of plano-multiradius reflective element assembly 130.Alternately, when actuator 136 comprises an electrically actuatedactuator that is electrically operable incorporating at least one motor,control 137 can comprise a switch (which, preferably, is operable undercontrol of the driver seated in cabin 125) or control 137 can comprise amemory controller, as known in the automotive mirror art, that controlsactuator 136 to move the position of plano-multiradius reflectiveelement assembly 130 to a pre-set orientation that suits the rearwardfield of view preference of an individual driver. Actuator 136 ismounted to bracket 138 which attaches to vehicle body side 111.Plano-multiradius reflective element assembly 130 is positionable byactuator 136 within exterior minor housing 140.

Plano-multiradius reflective element assembly 130, as shown in FIG. 11,comprises a plano element 150 and a separate multiradius element 155.Preferably, plano element 150 is adjacent to multiradius element at ajoint. At their joint, plano element 150 and separate multiradiuselement 155 can touch leaving substantially no gap or spacetherebetween, or plano element 150 and separate multiradius element 155can be spaced apart at their joint by a space or gap, as in FIG. 11.Plano element 150 and multiradius element 155 are both mounted tosurface 159 of, and are both supported by, a single backing plateelement 160. Plano element 150 and multiradius element 155 aredemarcated apart by demarcation element 165. Surface 161 of backingplate element 160 is preferably adapted to attach, such as by attachmentmember 164, to actuator 136 when plano-multiradius reflective elementassembly 130 is mounted in driver-side exterior sideview mirror assembly112 (and/or in passenger-side exterior side view mirror assembly 114)such that plano element 150 and multiradius element 155 are adjusted andpositioned in tandem and simultaneously when the driver (oralternatively, when a minor memory system, as is conventional in therearview minor arts) activates actuator 136 to reposition the rearwardfield of view of plano-multiradius reflective element assembly 130.Thus, since elements 150, 155 are part of plano-multiradius reflectiveelement assembly 130, movement of plano-multiradius reflective elementassembly 130 by actuator 136 simultaneously and similarly moves planoelement 150 and multiradius element 155.

Plano element 150 preferably comprises a flat reflector-coated glasssubstrate having unit magnification, and comprises a reflective surfacethrough which the angular height and width of the image of an object isequal to the angular height and width of the object when viewed at thesame distance (except for flaws that do not exceed normal manufacturingtolerances). Plano element 150 may comprise a conventional fixedreflectance minor reflector or it may comprise a variable reflectancemirror reflector whose reflectivity is electrically adjustable. Forexample, plano element 150 may comprise a flat glass substrate coatedwith a metallic reflector coating such as a chromium coating, a titaniumcoating, a rhodium coating, a metal alloy coating, a nickel-alloycoating, a silver coating, an aluminum coating (or any alloy orcombination of these metal reflectors). The metal reflector coating ofplano element 150 may be a first surface coating (such as on surface166) or a second surface coating (such as on surface 167), as such termsare known in the minor art. The reflector coating on plano element 150may also comprise a dielectric coating, or a multilayer of dielectriccoatings, or a combination of a metal layer and a dielectric layer toform automotive minor reflectors as known in the automotive minor art.If a variable reflectance reflector element, plano element 150preferably comprises an electro-optic reflector element and, mostpreferably, an electrochromic reflector element.

When mounted into exterior side view minor assembly 112 and/or 114,plano-multiradius reflective element assembly 130 is preferablyorientated so that at least a portion of (more preferably a substantialportion of) the reflector surface of plano element 150 is positionedcloser to the vehicle body (and hence to the driver) than any portion ofthe reflector surface of multiradius element 155. Thus, and referring toFIG. 11, side A of plano element 150 of plano-multiradius reflectiveelement assembly 130 is positioned closer to the driver than side D ofmultiradius element 155 when plano-multiradius reflective elementassembly 130 is mounted on an automobile. Also, when mounted intoexterior side view minor assembly 112 and/or 114, surfaces 166, 168 ofplano-multiradius reflective element assembly 130 face rearwardly interms of the direction of vehicle travel.

Multiradius element 155 of plano-multiradius reflective element assembly130 preferably comprises a curved/bent mirrored glass substrate. Thedegree of curvature preferably increases (and hence the local radius ofcurvature decreases) across the surface of multiradius element 155 withthe least curvature (largest radius of curvature) occurring at the sideof multiradius element 155 (side C in FIG. 11) positioned adjacent itsjoint to plano element 150 when both are mounted on backing plateelement 160. Thus, and referring to FIG. 11, the local radius ofcurvature at side C of multiradius element 155, when mounted on backingplate element 160, is larger than at side D. Also, the local radius ofcurvature preferably progressively decreases across multiradius element155 from side C to side D. Preferably, the local radius of curvature atside C of multiradius element 155 is at least about 1000 mm; morepreferably is at least about 2000 mm and most preferably is at leastabout 3000 mm whereas the local radius of curvature at side D ofmultiradius element 155 is, preferably, less than about 750 mm, morepreferably less than about 350 mm; most preferably less than about 150mm. Preferably, multiradius element 155 comprises a bent glass substratewith radii of curvature in the range of from about 4000 mm to about 50mm. The multiradius prescription for the multiradius element to be usedin a particular exterior minor assembly can vary according to thespecific field of view needs on a specific automobile model.

The total field of view rearwardly of the automobile of theplano-auxiliary reflective element assembly (which is a combination ofthe field of view of the plano reflective element and of the auxiliaryreflective element) preferably generally subtends an angle of at leastabout 20 degrees (and more preferably, generally subtends an angle of atleast about 25 degrees and most preferably, generally subtends an angleof at least about 30 degrees) with respect to the side of an automobileto which is attached an exterior sideview minor assembly equipped withthe plano-auxiliary reflective element assembly.

Multiradius element 155 may comprise a conventional fixed reflectanceminor reflector or it may comprise a variable reflectance minorreflector whose reflectivity is electrically adjustable. For example,multiradius element 155 may comprise a flat glass substrate coated witha metallic reflector coating such as a chromium coating, a titaniumcoating, a rhodium coating, a metal alloy coating, a nickel-alloycoating, a silver coating, an aluminum coating (or any alloy orcombination of these metal reflectors). The metal reflector coating ofmultiradius element 155 may be a first surface coating (such as onsurface 168) or a second surface coating (such as on surface 169), assuch terms are known in the minor art. The reflector coating onmultiradius element 155 may also comprise a dielectric coating, or amultilayer of dielectric coatings, or a combination of a metal layer anda dielectric layer to form automotive minor reflectors as known in theautomotive minor art. If a variable reflectance reflector element,multiradius element 155 preferably comprises an electro-optic reflectorelement and, most preferably, an electrochromic reflector element.

Also, it is preferable that the thickness of plano element 150 andmultiradius element 155 be substantially the same in dimension so thattheir respective outer surfaces, 166 and 168, are substantially coplanarso that a driver can readily view images in either or both elements. Thethickness dimension of elements 150, 155 is determined by the thicknessof the substrate (or in the case of laminate-type electrochromicreflective elements, the thickness of the two substrates between whichthe electrochromic medium is disposed). For example, plano element 150and/or multiradius element 155 can comprise a reflector coated glasssubstrate or panel of thickness preferably equal to or less than about2.3 mm, more preferably equal to or less than about 1.6 mm, mostpreferably equal to or less than about 1.1 mm. Use of a thinnersubstrate is beneficial in terms of improving the overallstability/vibration performance of the image seen in plano-multiradiusreflective element assembly 130 when mounted to an automobile.

The reflector area of plano element 150 is preferably larger than thatof multiradius element 155. Preferably, the width dimension of planoelement 150 is larger than the width dimension of multiradius element155 (both width dimensions measured at their respective widest dimensionand with the width of the respective element being gauged with therespective element oriented as it would be orientated when mounted onthe automobile). Thus, and referring to FIG. 11, the distance from sideA to side B of plano element 150 is larger than the distance from side Cto side D of multiradius element 155. Thus, the ratio of the width ofplano element 150 to the width of multiradius element 155 is preferablygreater than 1; more preferably greater than 1.5; most preferablygreater than 2.5 in order to provide a large, unit magnification planoelement 150 as the principal rear viewing portion of plano-multiradiusreflective element assembly 130 and providing multiradius element 155 asa smaller, auxiliary, separate, wide-angle viewing portion ofplano-multiradius reflective element assembly 130. For plano-multiradiusreflective element assemblies to be mounted to the exterior sideviewassemblies of passenger automobiles used non-commercially and fornon-towing purpose, the width of plano element 150 (at its widestdimension) is preferably in the range of from about 50 mm to about 225mm; more preferably in the range of from about 75 mm to about 175 mm;most preferably in the range of from about 100 mm to about 150 mm.

Backing plate element 160 is preferably a rigid polymeric substratecapable of supporting plano element 50 and multiradius element 155.Backing plate element 160 comprises a flat portion (generally between Eand F as shown in FIG. 11) that corresponds to and is aligned with planoelement 150. Backing plate element 60 also comprises a curved portion(generally between G and H as shown in FIG. 11) that corresponds to andis aligned with multiradius element 155. Preferably, curved portion G-Hof multiradius element 155 is fabricated with a multiradius prescriptionthat is substantially the same as the multiradius prescription ofmultiradius element 155. Backing plate element 160 is formed as a singleelement to which elements 150 and 155 are separately attached.Preferably, backing plate element 160 is formed by injection molding ofa thermoplastic or a thermosetting polymer resin. Materials suitable touse for backing plate element 160 include unfilled or filled polymericmaterials such as glass and/or mineral filled nylon or glass and/ormineral filled polypropylene, ABS, polyurethane and similar polymericmaterials. For example, backing plate element 160 can be formed of ABSin an injection molding operation. Plano element 150 can be cut from astock lite of flat chromium minor-coated 1.6 mm thick glass. Multiradiuselement 155 can be cut from a stock lite of multiradiusly-bent chromiummirror-coated 1.6 mm thick glass. Plano element 150 and multiradiuselement 155 can then be attached (such as by an adhesive attachment suchas an adhesive pad or by mechanical attachment such by clips, fastenersor the like) to the already molded backing plate element 160.Alternatively, plano element 150 and multiradius element 155 can each byindividually loaded into an injection molding tool. Once loaded, apolymeric resin (or the monomers to form a polymeric resin) can beinjected into the mold in order to integrally form backing plate element160 with elements 150, 155 integrally molded thereto. Integral moldingof the backing plate element to plano element 150 and multiradiuselement 155 (along with any other elements such as the demarcationelement 165) in a single integral molding operation, is a preferredfabrication process for plano-multiradius reflective element assembly130.

Plano-multiradius reflective element assembly 130 further preferablyincludes demarcation element 165 that functions to delineate anddemarcate the plano region of the assembly from the wide-angle,multiradius region and also preferably functions to preventingress ofdebris, dirt, water and similar contaminants (such as road splash, carwash spray, rain, snow, ice, leaves, bugs and similar items thatplano-multiradius reflective element assembly 130 would be subject towhen mounted and used on an automobile) into any gap between planoelement 150 and multiradius element 155 when both are attached tobacking plate element 160. Optionally, at least a portion of demarcationelement 165 can be disposed in any gap between plano element 150 andmultiradius element 155 at their joint on backing plate element 160.Preferably, demarcation element 165 is formed of a polymeric materialthat is dark colored (such as black or dark blue or dark brown or darkgrey or a similar dark color) such as a dark colored polypropylene resinor a dark colored nylon resin or a dark colored polyurethane resin or adark colored polyvinyl chloride resin or a dark colored siliconematerial. Most preferably demarcation element 165 is formed of an atleast partially elastomeric material (such as silicone, or EPDM, orplasticized PVC or the like) in order to provide a degree of vibrationdampening for elements 150, 155. As shown in FIG. 12, demarcationelement 165 optionally includes a crown portion 170 that includes wingportions 173, 173′ and a stem portion 171. Stem portion 171 preferablyhas a cross-sectional width CCC of less than about 4 mm, more preferablyless than about 3 mm and, most preferably less than about 2 mm. Crownportion 170 preferably is dimensioned to not protrude substantiallybeyond surfaces 166, 168 of elements 150, 155 when demarcation element165 is installed between elements 150 and 155. Also, wings 173, 173′ arepreferably dimensioned to protrude (most preferably slightly) ontosurfaces 166, 168 of elements 150, 155 when demarcation element 165 isinstalled between elements 150 and 155 in order to provide a weatherbarrier seal and/or to at least partially accommodate any dimensionaltolerances of elements 150, 155 that could lead to variation in theinter-element gap between sides C and B. While the demarcation elementshown in FIG. 12 is one embodiment, other constructions are possibleincluding a demarcation element that has minimal or no crown portionLikewise, a demarcation element can have little or no stem portion,especially when the joint between plano element 150 and multiradiuselement 155 includes no gap to receive a stem. Also, where a gap at theplano to multiradius joint exists, any stem of the demarcation elementcan at least partially be disposed in such gap so as to at leastpartially fill the gap (or it can optionally substantially fill thegap). Optionally, demarcation element 165 is fabricated by injectionmolding of a polymeric resin. After plano element 150 and multiradiuselement 155 have been attached to backing plate element 160, aseparately formed demarcation element 165 can then be inserted (andsecured such as by an adhesive or by a mechanical attachment such as bya fastener) into a space between elements 150 and 155. Note that,optionally, side B of plano element 150 and side C of multiradiuselement 155 can touch (leaving substantially no gap or spacetherebetween). In such a situation, demarcation element 165 can comprisea dark colored strip such as of a tape or of a plastic film that coversthe joint between elements 150 and 155. Alternatively, demarcationelement 165 can comprise a preferably dark-colored paint, lacquer, caulkor similar material that can be applied to, and that can preferably fillinto, the joint between elements 150 and 155. The width of the portionof demarcation element 165 that is visible to the driver is preferablyless than about 4 mm, more preferably less than about 3 mm and mostpreferably less than about 2 mm, but is equal to or greater than about0.5 mm, more preferably is equal to or greater than about 0.75 mm, mostpreferably is equal to or greater than about 1 mm in order to provideadequate demarcation of the plano region from the multiradius radiusregion without unduly obscuring the rearward field of view of therespective elements. Optionally, demarcation element 165 can be formedas part of backing plate element 160 such as by forming demarcationelement 165 as a wall structure of the backing plate element thatpartitions backing plate element 160 into two regions: A first regionadapted to receive plano reflective element 150 and a separate andadjacent second region adapted to receive multiradius reflective element155.

Thus, and referring to FIG. 14, a second embodiment of plano-multiradiusreflective element assembly 130′ may include a backing plate element160′ which comprises a plate molded from a polymer resin (such as apolyolefin such as polypropylene or such as ABS or nylon) with ademarcation element 165′ that is molded as a wall structure thatpartitions backing plate element 165′ into a first region (from CC toBB) adapted to receive and accommodate plano reflective element 150′ andinto a second region (from BB to AA) adapted to receive and accommodatewide-angle optic multiradius reflective element 155′. Note that sectionAA to BB of backing plate element 160′ is angled to section BB to CC.Such angling of the auxiliary reflective element relative to the planoelement can be advantageous in allowing the auxiliary reflective elementview a portion of the road adjacent the automobile that is in a blindspot of the plano reflective element. In this regard, it is preferablethat the multiradius element be angled away from the plane of the planoelement, as shown in FIG. 14 by the angling of section AA to BB tosection BB to CC.

Preferably, demarcation element 165 is formed in an integral moldingoperation, along with formation of backing plate element 160, andattachment of elements 150, 155 thereto. For example, plano element 150and multiradius element 155 can each by individually loaded into aninjection molding tool. Once loaded, a polymeric resin (or the monomersto form a polymeric resin) can be injected into the mold in order tointegrally form backing plate element 160 with elements 150, 155integrally molded thereto and, in the same molding operation and in thesame tool, also form by molding the demarcation element. Integralmolding of the backing plate element to plano element 150 andmultiradius element 155 along with creation in the single moldingoperation of demarcation element 165 (along with any other elements suchas attachment member 164) in a single integral molding operation, is apreferred fabrication process for plano-multiradius reflective elementassembly 130. By loading all the sub components of plano-multiradiusreflective element assembly 130 into a molding tool, and then injectingpolymeric resin to form the backing plate, demarcation member and anyattachment member, a substantially complete or fully completeplano-multiradius reflective element assembly can be unloaded from thetool at the completion of the integral molding operation (as known inthe molding art), thus enabling economy in manufacturing andaccommodation of any dimensional tolerances in the sub components. Whereintegral molding is so used, it is preferable to use a reactive moldingoperation such as reactive injection molding of a urethane as suchreactive injection molding operations occur at relatively modesttemperatures.

Plano element 150 and/or multiradius element 155 can comprise a heaterelement, as known in the automotive mirror art, that is operable todeice/demist surfaces 166, 168. Such heater elements are conventionaland can comprise a positive temperature coefficient heater pad, aresistive heater element and/or a conductive coating. Plano element 150and/or multiradius element 155 can also optionally comprise ascatterproofing member, as known in the automotive mirror art, such asan adhesive tape, to enhance safety in an accident.

Also, plano element 150 and/or multiradius element 155 can comprise avariable reflectance electro-optic element such as an electrochromicmirror reflector. Thus, both element 150 and element 155 can comprise anelectrochromic minor element or either of element 150 and element 155can comprise an electrochromic minor element and the other can comprisea fixed reflectance non-variable reflectance minor element such as ametal reflector coated glass panel such as a chromium coated glasssubstrate. Also, if both plano element 150 and multiradius element 155comprise an electro-optic element such as an electrochromic minorelement capable of electrically dimmable reflectivity, both elements150, 155 can dim together and in tandem under control of a commondimming control signal (typically provided by an electro-optic automaticdimming interior mirror assembly mounted in the cabin of the automobileand equipped with photosensors to detect incident glare and ambientlight). Alternately, if both plano element 150 and multiradius element155 comprise an electrooptic element such as an electrochromic mirrorelement capable of electrically dimmable reflectivity, element 150 candim independently of element 155 (such as is disclosed in U.S. Pat. No.5,550,677, the entire disclosure of which is incorporated by referencein U.S. Pat. No. 6,717,712, incorporated herein above). If either orboth of elements 150, 155 comprise an electrochromic element,preferably, the electrochromic reflective element comprises a frontsubstrate and a rear substrate with an electrochromic medium disposedbetween, such as a solid polymer matrix electrochromic medium such as isdisclosed in U.S. patent application Ser. No. 09/350,930, filed Jul. 12,1999, entitled “ELECTROCHROMIC POLYMERIC SOLID FILMS, MANUFACTURINGELECTROCHROMIC DEVICES USING SUCH FILMS, AND PROCESSES FOR MAKING SUCHSOLID FILMS AND DEVICES” to Desaraju V. Varaprasad et al., now U.S. Pat.No. 6,154,306, or such as is disclosed in U.S. Pat. Nos. 5,668,663;5,724,187; 5,910,854; and 5,239,405, the entire disclosures of which areincorporated by reference in U.S. Pat. No. 6,717,712, incorporatedherein above. Most preferably, in such laminate-type electrochromicminor reflective elements, the front substrate comprises a glass plateof thickness less than about 1.6 mm, most preferably about 1.1 mmthickness or lower, and the rear substrate comprises a glass plate ofthickness equal to or greater than about 1.6 mm, more preferably greaterthan about 1.8 mm thickness, most preferably equal to or greater thanabout 2.0 mm thickness. The rearmost surface of the rear substrate (thefourth surface as known in the mirror art) is reflector coated with ahigh reflecting metal film such as of aluminum or silver, or an alloy ofaluminum or silver. Most preferably, the front-most surface of the rearsubstrate (the third surface as known in the minor art) is reflectorcoated with a high reflecting metal film such as of aluminum or silver,or an alloy of aluminum or silver.

Backing plate element 165 of plano-multiradius reflective elementassembly 130 is optionally equipped on its rearmost surface withattachment member 164 to facilitate attachment to thereflector-positioning actuator of the exterior sideview minor assemblythat plano-multiradius reflective element assembly 130 is mounted to.Attachment of plano-multiradius reflective element assembly 130 to theactuator can be by mechanical attachment such as by a tab, clip orfastener, or may be by adhesive attachment such as by a siliconeadhesive, a urethane adhesive or a similar adhesive material such as atape coated on both surfaces with a pressure sensitive adhesive to forma “double-sticky” tape. The exterior sideview mirror assembly, on whoseminor reflector-positioning actuator the plano-multiradius reflectiveelement assembly is mounted, can be a fixedly attached exterior sideviewminor assembly, a break-away exterior sideview minor assembly and apowerfold exterior sideview minor assembly, as known in the automotiveminor art.

FIGS. 13A-13H shows various arrangements of multiradius reflectiveelement 155 relative to its adjacent plano reflective element 150 (withdemarcation element 165 disposed at their joint). In FIGS. 13A, 13B,13C, 13E and 13F, plano element 150 is mounted wholly inboard ofmultiradius element 155. Thus, in FIGS. 13A, 13B, 13C, 13E and 13F,plano element 150 would be disposed closer to the vehicle body (andhence to the driver) than multiradius element 155 when plano-multiradiusreflective element assembly 130 was mounted in an exterior sideviewmirror attached to a side of an automobile. Therefore, in FIGS. 13A,13B, 13C, 13E and 13F, plano element 150 would be mounted inboardrelative to the side of the automobile and multiradius element 155 wouldbe mounted outboard relative to the side of the automobile. In general,the location of the multiradius reflective element in the outboard,upper portion of the plano-multiradius reflective element assembly, asin FIGS. 13B and 13E, is preferred as this allows the plano portionprovide a desired rearward field of view along the side of the vehicle.The configuration as shown in FIG. 13G (where the multiradius reflectiveelement is along the inboard side of the assembly) is also desirable asthis allows the driver view the side of the vehicle (something manydrivers desire in order to have a frame of reference for their rearwardfield of view) while facilitating having a wide field of view for theplano portion.

Unlike trucks, busses and commercial vehicles the size of an exteriorsideview minor assembly suitable for use on an automobile (andespecially when the automobile is not towing a trailer or the like) isrestricted. Automobiles generally are non-commercial vehicles intendedfor personal transportation. Automobiles typically carry 5 passengers orless, although minivans and large sports utility vehicles (which areclassified herein as automobiles) can have seat accommodation for up to10 passengers (although accommodation for 7 passengers or less is morecommon). The tandem mounting of a plano element of unit magnificationand a separate auxiliary element onto a common, single backing plateelement, and the mounting of this backing plate element onto an actuatorof an exterior sideview mirror assembly so that a driver cansimultaneously and similarly move the auxiliary element and the planoelement so as to position their respective rearward fields of view, andto achieve this within the relatively restricted space available in astandard automobile-sized exterior sideview mirror assembly is animportant element of this present invention. By utilizing a planoelement of unit magnification in the plano-multiradius reflectiveelement assembly, and by sizing the reflector area of the plano elementlarger than the reflector area of the multiradius element and,preferably, by sizing the reflector area of the plano element at asufficiently large size that the rearward field of view provided by theplano element alone meets and satisfies the minimum field of viewrequirement mandated by an automaker specification and/or a governmentregulation, the need to provide a safety warning indicia such as“OBJECTS N MIRROR ARE CLOSER THAN THEY APPEAR” in the plano elementand/or in the multiradius element can be obviated. Preferably, the planoelement comprises a reflector surface area of a size sufficient, whenmounted as part of a plano-multiradius reflective element assembly in adriver-side exterior sideview mirror assembly on an automobile, toprovide the driver of the automobile a view of a level road surfaceextending to the horizon from a line, perpendicular to a longitudinalplane tangent to the driver's side of the automobile at the widestpoint, extending 8 feet out from the tangent plane 35 feet behind thedriver's eyes (at a nominal location appropriate for any 95th percentilemale driver or at the driver's eye reference points established inFederal Motor Vehicle Standard No. 104), with the driver seated in thedriver's seat and with the driver's seat in the rearmost position. Also,preferably, the aspect ratio of the plano-multiradius reflective elementassembly (defined as the ratio of its largest vertical dimension to itslargest horizontal dimension, measured with the plano-multiradiusreflective element assembly oriented as it would be oriented whenmounted in an exterior sideview mirror assembly on an automobile, andwith “horizontal” being generally parallel with the road surface theautomobile travels on and “vertical” being generally perpendicular tothe road surface the automobile travels on) is preferably less than 1,more preferably less than 0.8, most preferably less than 0.6. Further,it is preferable that the multiradius element be disposed outboard(relative to the side of the vehicle and with the plano-multiradiusreflective element assembly oriented as it would be when mounted in anexterior sideview minor assembly on an automobile) on theplano-multiradius reflective element assembly so that the multiradiuselement is positioned to provide an auxiliary, wide-angle view of a“blind-spot” region in an adjacent sidelane while the moreinboard-disposed plano element with unit magnification provides theprincipal sideview image to the driver.

Also, it is preferable that the principal axis of the rearward field ofview of the multiradius element be different from and angled to theprincipal axis of the rearward field of view of the plano element whenboth are attached to the backing plate element of the plano-multiradiusreflective element assembly and when the plano-multiradius reflectiveelement assembly is mounted and operated in an exterior sideview mirrorassembly on an automobile. Preferably, the principal axis of therearward field of view of the plano element is directed generallyparallel to the road that the automobile equipped with theplano-multiradius reflective element assembly is travelling on (i.e.generally parallel to the longitudinal axis of the automobile) so as toprovide the driver with a long-distance view of approaching vehicles inthe side lane that the plano element views). However, preferably theprincipal axis of the rearward field of view of the multiradius elementof, for example, a door-mounted driver-side (or passenger-side) exteriorsideview mirror assembly in which the plano-multiradius reflectiveelement assembly is mounted is directed generally downwardly towards theroad surface adjacent to the driver seating location and/or several feet(such as about 1 foot to about 24 feet; more preferably, about 1 foot toabout 12 feet; most preferably about 1 foot to about 8 feet in distance)to its rear (in order to capture a field of view of a rear approachingvehicle that is approaching to overtake, or is about to overtake, or isovertaking the automobile equipped with the plano-multiradius reflectiveelement assembly). Thus, preferably, the principal axis of the rearwardfield of view of the multiradius element is angled and directedgenerally downwardly with respect to the longitudinal axis of theautomobile and thus is at an angle to the principal axis of the rearwardfield of view of the plano element. For example, multiradius element155′ when attached to surface 173″ of backing plate 160′ (see FIG. 14B)would have its principal axis of rearward view as indicated by 180′ asin FIG. 14B, and as such would be canted towards the road surface whenmounted in an exterior sideview mirror assembly attached to the side ofan automobile. By contrast, plano element 150′ when attached to surface174′ of backing plate 160′ (see FIG. 14A) would have a principal axis asindicated by 185′ as in FIG. 14A and, as such, would be generallyparallel to the road surface when mounted in an exterior sideview mirrorassembly attached to the side of an automobile. Having the multiradiuselement canted somewhat downwards towards the road surface assistsvisual detection by the driver of overtaking vehicles in the traditional“blind-spot” in the adjacent side lane. The angle that the multiradiuselement is angled on the backing plate element of the plano-multiradiusreflective element assembly relative to the plane of the planoreflective element will vary from automobile model to model, butgenerally is preferred to be in the about 1 degree to about 10 degreesrange; about 2 degrees to about 8 degrees range more preferred; andabout 3 degrees to about 6 degrees range most preferred. In order toconveniently achieve an angling of the multiradius portion with respectto the plano portion (and preferably a downward angling), the portion ofthe backing plate element that the multiradius reflective element isattached to can be angled relative to the adjacent portion of thebacking plate element that the plano reflective portion is attached to.Thus, and referring to FIG. 14, plano-multiradius reflective elementassembly 130′ includes a molded polymeric backing plate element 160′comprising a generally flat portion 162′ (between BB and CC in FIG. 14)and an adjacent curved portion 161′ (between AA and BB). As indicated by190′ and 195′, portion AA to BB of backing plate element 160′ isgenerally angled to portion BB to CC of backing plate 160′. Preferably,the portion of backing plate element 160′ to which the auxiliaryreflective element attaches is angled towards the front (compared to theangling of plano reflective element) of an automobile equipped with theplano-auxiliary reflective element assembly of the present invention.FIG. 14 is a view of plano-multiradius reflective element assembly 130′as it would appear from above the vehicle as it would be orientated inuse (with portion 162′ closer to the driver than portion 161′). The wallsection, section XX in FIG. 14, taken through section 162′ of backingplate element 160′ is of substantially constant dimension (asillustrated in FIG. 14A) whereas the wall section, section YY in FIG.14B, taken through section 161′ of backing plate element 160′ is ofvarying dimension and is angled. Plano reflective element 150′ andmultiradius reflective element 155′ (for example, plano element 150′ cancomprise an electrochromic minor element and multiradius element 155′can comprise a chrome coated glass reflector) are attached to portions162′ and 161′, respectively. By being supported on the angled face 173″(see FIG. 14B) of portion 161′, the principal viewing axis ofmultiradius reflector element 155′ is angled downwards towards the roadsurface, as compared to the more horizontal-viewing principal viewingaxis of plano element 150′, when plano-multiradius reflective element130′ is mounted in an exterior sideview mirror assembly on anautomobile. Demarcation element 165′ is preferably molded in the samemolding tool as is used to mold backing plate element 160′, and sodemarcation element 165′ is formed as an integral part of backing plateelement 160′, forming a wall thereof that partitions the surface ofbacking plate element 160′ into a region for receiving the planoreflective element 150′ and a region for receiving the auxiliaryreflective element 155′. Also, end-caps 170′ and 171′ are optionallyprovided. Plano reflective element 150′ can attach into the cavityformed between demarcation element 165′ and end-cap 171′; multiradiusreflective element 155′ can attach into the cavity formed betweendemarcation element 165′ and end-cap 170′. Note that the portion of thebacking plate element where the wide-angle optic multiradius elementattaches can have a thicker wall thickness than that of the portion ofthe backing plate element where the unit magnification optic elementattaches in order to allow for the angling of the multiradius elementdownwardly relative to the angle of the plano element, as illustrated inFIGS. 14A-B. As illustrated in FIGS. 14A-B, the angle downwards to thelongitudinal axis of the vehicle of the multiradius element cangenerally be set by an angling of a surface of the backing plate elementin order to ensure that the principal axis of the rearward field of viewof the plano element is directed generally parallel to the longitudinalaxis of an automobile equipped with the plano-multiradius reflectiveelement assembly and that the principal axis of the rearward field ofview of the multiradius element is directed generally at an angledownwards to the longitudinal axis of the automobile.

Note that the provision of the plano-multiradius reflective elementassembly of this invention as a unitary module has manufacturingadvantages, particularly for exterior sideview minor assemblymanufacturers who can procure a plano-multiradius reflective elementassembly module from a mirror reflector supplier and then mount theplano-multiradius reflective element assembly module onto an actuator.

Referring to FIG. 15, a third embodiment 230 of a plano-multiradiusreflective element assembly is illustrated. Plano-multiradius reflectiveelement assembly 230 includes a plano reflective element 250 and aseparate multiradius reflective element assembly 255, both individuallyattached to a backing plate element, and with demarcation element 265disposed at their joint. Plano-multiradius reflective element assembly230 is about 8.5 inches wide and about 4.25 inches tall (aspect ratio of0.5), at their largest dimension. Shown as the shaded triangle 240 inplano reflective element 250 is the image of a triangular target objectset about 35 feet rearward and of width about 8 feet and of height ofabout 4.1 feet as would be seen were plano-multiradius reflectiveelement assembly 230 mounted in a driver-side exterior sideview mirrorassembly in an automobile such as a sports utility vehicle. In general,it is desirable that the plano reflective element be dimensioned andconfigured so as to have its rearward field of view capture an image(that is visible, by reflection in the plano reflective element, to adriver seated in the driver's seat in an automobile to which is attachedan exterior sideview mirror assembly equipped with the plano-auxiliaryreflective element assembly according to this present invention) of atriangular shaped target located about 35 feet rearward of the driverseating location, extending about 8 feet out from the plane defined bythe side of the automobile and reaching a height of between about 4 feetand about 5 feet from the road surface at that location 35 feet rearwardof the automobile. The total field of view rearwardly of the vehicle ofplano-multiradius reflective element assembly 230 (which is acombination of the field of view of plano reflective element 250 and ofthe auxiliary multiradius reflective element 255) preferably generallysubtends an angle of at least about 30 degrees (and more preferably,generally subtends an angle of at least about 35 degrees and mostpreferably, generally subtends an angle of at least about 40 degrees)with respect to the side of an automobile to which is attached anexterior sideview minor assembly equipped with plano-multiradiusreflective element assembly 230.

Referring to FIG. 16, another embodiment 310 of the plano-auxiliaryreflective element assembly of the present invention is illustrated.Plano-auxiliary reflective element assembly 310 includes a firstreflective element 312 and a second or auxiliary, separate reflectiveelement 314 which are together supported in a frame element assembly316. As will be more fully described below, frame element assembly 316is adapted such that when reflective elements 312 and 314 are placed, orotherwise positioned, in frame element assembly 316, the angularorientation of each reflective element is pre-established such thatduring assembly, the assembler need simply place the reflective elementsin frame element assembly 316.

In the illustrated embodiment, frame element assembly 316 includes aframe 318 with a forward facing open portion 318 a (FIG. 17) (and thuswhen frame element assembly 316 is mounted in a vehicle-mounted exteriorsideview mirror assembly, the forward facing open portion (318 a) isfacing to the front of the vehicle) through which a reflective elementsubassembly 317 a, which includes reflective element 312, is positionedin frame element assembly 316 and a rearward facing open portion 318 b(FIG. 16) (which faces the rear of the vehicle when frame elementassembly 316 is mounted in a vehicle mounted exterior sideview mirrorassembly) in which a second reflective element subassembly 317 b, whichincludes reflective element 314, is positioned in frame element assembly316. Frame 318 preferably comprises a molded member formed from aplastic material, such as a reinforced nylon.

In preferred form, first reflective element 312 comprises a planoreflective element 350, such as a flat reflector coated glass substrate,with a reflective surface through which the angular height and width ofan image of an object is equal to the angular height and width of theobject when viewed to the same distance (except for flaws that do notexceed normal manufacturing tolerances) so as to have a unitmagnification. Similar to the previous embodiment, plano reflectiveelement 350 may comprise a conventional fixed reflectance reflectiveelement or may comprise a variable reflectance reflective element who'sreflectivity is electrically adjustable, as is known in the art. Forexample, plano reflective element 350 may comprise a flat glasssubstrate coated with metallic reflector coating, such as a chromiumcoating, titanium coating, rhodium coating, metal alloy coating, nickelalloy coating, silver coating, aluminum coating, or any alloy orcomposition of these metal reflectors. For further details of planoreflective element 350, reference is made to the previous embodiments.

In the illustrated embodiment, reflective element 312 comprises anelectrochromic reflective element and includes a first substrate 312 aand a second substrate 312 b with an electrochromic medium 312 cdisposed between first and second substrates 312 a, 312 b. Such suitableelectrochromic media include, for example, a solid polymer matrixelectrochromic medium as noted in reference to the previous embodiments.Electrical connectors 320 a and 320 b are coupled to the electrochromicmedium 312 c to provide a potential across the electrochromic mediumwhich induces the electrochromic medium to darken, as is known in theart. In the illustrated embodiment, reflective element subassembly 317 aalso includes an optional heater pad 322, which is disposed behindreflective element 312, and a vibration reducing element, such as a foampad 326, positioned behind heater pad 322, which absorbs vibration ofreflective element 312.

Referring again to FIG. 17, frame 318 is adapted to receive and supportreflective element subassembly 317 a, which is mounted to frame 318 by abacking plate 324, such as a plastic backing plate. In the illustratedembodiment, backing plate 324 mounts to the inner perimeter portion offrame 318 using conventional techniques, such as by adhesive bonding,heatstaking, snap-fit coupling, welding, or the like, to form part offrame element assembly 316. Alternatively, backing plate 324 may mountonto foam pad 326, for example, by an adhesive attachment, such asdouble sided sticky tape. In which case, reflective element 312 may bemounted to an inner surface of frame 318, such as by an adhesiveattachment, including for example a silicone adhesive, with heater pad322 mounted to reflective element 312, such as by an adhesiveattachment, and foam pad 326 mounted to heater pad 322, such as by anadhesive attachment including, for example, double-sided sticky tape.

Frame element assembly 316 mounts reflective element assembly 310 in theminor casing and preferably on an actuator, such as an electricactuator, which permits adjustment to the orientation of reflectiveelement assembly 310 about one or more axis. Examples of suitableactuators are described in U.S. Pat. Nos. 5,900,999; 5,986,364;6,132,052; 6,037,689; and 6,094,027 and application Ser. No. 09/277,632,filed Mar. 26, 1999, now U.S. Pat. No. 6,229,226, and Ser. No.09/408,867, filed Sep. 29, 1999, now U.S. Pat. No. 6,243,218, which areincorporated by reference in their entireties in U.S. Pat. No. 6,717,712(incorporated herein above). Optionally and preferably, backing plate324 is adapted to engage or be engaged by the actuator for repositioningof plano-auxiliary reflective element assembly 310 about one or moreaxes. In this manner, the orientation of both reflective element 312 andreflective element 314 are simultaneously adjusted by the actuator. Asbest seen in FIG. 17, forward facing side 324 a of backing plate 324includes mounting structures 324 b which are engaged by the actuator tothereby mount reflective element assembly 310 in the mirror casing.

Referring again to FIG. 16, frame 318 is a unitary frame and includes afirst bezel portion 330 which extends around reflective element 312 anda second bezel portion 332 which extends around reflective element 314to provide styling utility as well as functional utility. In thismanner, a portion of forward facing side of frame 318 forms a supportsurface for reflective element 312, while a portion of rearward facingside of frame 318 forms first bezel portion 330. Similarly, anotherportion of the rearward facing side of frame provides support forreflective element 314 and also provides bezel portion 332. In addition,a portion of frame 318 forms a demarcation element at the juncture ofreflective elements 312 and 314. In the illustrated embodiment, thedemarcation element is formed by a section or portion of bezel portion330, which will be described in greater detail in reference to bezelportion 330. Thus, frame element assembly 316 provides a supportfunction, a positioning function, including an angling function, whilealso serving to provide styling utility and a demarcation function.

Second reflective element 314 comprises a radiused reflective elementand, more preferably, a multiradiused reflective element 355 having amultiradiused curvature. For example, the radii of curvature ofreflective element 314 may range from about 4000 mm to about 100 mm and,preferably, range from about 3000 mm to about 150 mm, and, mostpreferably, range from about 2000 mm to about 200 mm. In addition,reflective element 314 may comprise a fixed reflectance reflectiveelement or may comprise a variable reflectance reflective element who'sreflectivity is electrically adjustable. Preferably, reflective elements312 and 314 include glass substrates, with at least the outer surface ofeach reflective element comprising glass. However, metalized plasticreflectors may also be used which is especially suitable for reflectiveelement 314. In which case, the reflective element (314) would beespecially suitable for molding in or along with frame 318, with thepreformed metalized substrate forming reflective element 314 beingplaced into the mold forming frame 318. For further details of othersuitable reflective elements, reference is made to the previousembodiments. In addition to reflective element 314, reflective elementsubassembly 317 b includes a vibration reducing element, such as a foampad 314 a, which is positioned behind reflective element 314. Similar toreflective element 312, foam pad 314 a is attached to reflective element314 by an adhesive attachment, such as a double-sided sticky tape and,similarly, is attached to frame 318 as will be more fully describedbelow.

As noted above, frame 318 includes a first bezel portion 330 and asecond bezel portion 332. In addition, frame 318 includes an auxiliarysupport element 320 that provides a mounting surface or support surfacefor reflective element subassembly 317 b. As best seen in FIGS. 17 and18, support element 320 includes a recessed support surface 328 which isangled to provide an angled support surface for reflective elementsubassembly 317 b. Thus, when reflective subassembly 317 b is positionedon and mounted on support surface 328, such as by an adhesive attachmentbetween foam pad 314 a and support surface 328, the orientation ofreflective element 314 is established by the angle of the supportsurface. Optionally, support element 320 includes gussets 321 a and 321b which project forwardly from the forward facing side of frame 318 tothereby reinforce support surface 328.

Referring to FIG. 16, first bezel portion 330 includes an upper portion330 a, two side portions 330 b and 330 c, and a lower portion 330 d.Side portion 330 b forms an acute angle with respect to the lowerportion 330 d and an obtuse angle with respect to upper portion 330 aand together with upper portion 330 a, side portion 330 c, and lowerportion 330 d form a perimeter around reflective element 312 to therebyform a styling feature. Second bezel portion 332 extends outwardly fromupper portion 330 a and downwardly to lower portion 330 d of firstperimeter portion 330 and together with side portion 330 b forms aperimeter around second reflective element 314. Support element 320extends behind and between side portion 330 b and second bezel portion332 so that reflective element 314 is recessed behind side portion 330 band bezel portion 332.

As best seen in FIG. 18, upper portion 330 a, side portions 330 b and330 a, and lower portion 330 d are substantially coplanar and togetherdefine an outer surface below which reflective element 312 is recessedwhen reflective element 312 is mounted in frame 318. In contrast,perimeter portion 332 is angled forwardly with respect to the plane inwhich upper portion 330 a, side portions 330 b and 330 c, and lowerportion 330 d lie. It should be understood that the terms “forwardly”,“rearwardly” and “downwardly”, are used in reference to when the minorsystem is mounted in an automobile. Therefore, “forwardly” is adirection heading toward the front of the automobile, “rearwardly” is adirection heading to the rear of the automobile, “outwardly” is adirection away from the side of the vehicle on which the minor assemblyis mounted, and “downwardly” is a direction heading toward the surfaceon which the vehicle is positioned (such as a ground or road surface).Similarly as noted above, reflective element 314 is recessed below anouter surface of perimeter portion 332 and also below the outer surfaceof side portion 330 b when mounted in frame 318.

As would be understood from FIGS. 17-19, support surface 328 is alsoangled forwardly with respect to back plate 324 and/or reflectiveelement 312 when frame element assembly 316 is mounted in an automobilemounted exterior sideview mirror system. In addition, support surface328 is also angled or tilted downwardly with respect to reflectiveelement 312 and/or backing plate 324 such that when reflective element314 is supported on support surface 328, reflective element 314 providesan increased field of view extending laterally or outwardly from thelongitudinal axis of the automobile and also downwardly of thelongitudinal axis of the automobile.

Referring to FIGS. 21 and 22, support surface 328 is configured suchthat reflective element 314 is tilted forwardly at an angle α withrespect to the X-axis of reflective element 312. In one form, angle α isin a range of about 0.75 degrees to about 5 degrees. In another form,angle α is in a range of about 1 degree to about 3 degrees. In yetanother form, angle α is in a range of about 1.25 degrees to about 2.5degrees. Reflective element 314 is also tilted downwardly with respectto the Y-axis of reflective element 312 at an angle β. In one form,angle β is in a range of about 0.75 degrees to about 5 degrees. Inanother form, angle β is in a range of about 1.5 degrees to about 3.5.In yet another form, angle β is in a range of about 2 degrees to about 3degrees. With the tilted orientation of reflective element 314,reflective element 314 provides a field of view with a principal axisthat sweeps outwardly and downwardly with respect to the principal axisof the field of view of reflective element 312.

In the illustrated embodiment, support surface 328 is provided by aplate member 321. Plate member 321 may comprise a solid plate member ora foraminous plate member. In the illustrated embodiment, plate member321 is integrally formed with perimeter portions 330 and 332 during themolding process of frame 318. As previously noted, frame 318 includes arearwardly facing opening 318 b through which reflective element 314 isinserted for placement on support surface 328. For example, reflectiveelement 314 may be positioned in frame 318 on support surface 328 duringthe molding process of frame 318, such as by insert molding, or may beinserted into frame 318 before the plastic material forming frame 318 isfully cured and is still pliable. In which case, reflective elementsubassembly 317 b is mounted to auxiliary support 320 by an adhesiveattachment or a mechanical attachment. Alternatively, support surface328 may be formed by peripheral flange or a frame. In this manner,reflective element subassembly 317 b may be placed in frame 318 from itsforward facing side.

Referring to FIG. 22, when reflective element assembly 310 is mounted ina vehicle reflective element 312 has a field of view 360 which forms anangle A with respect to the longitudinal center line of the vehicle in arange of about 8 degrees to about 20 degrees. In another form, angle Ais in a range of about 10 degrees to about 18 degrees. In yet anotherform, angle A is in a range of about 12 degrees to about 16 degrees.Similarly, reflective element 314 has a field of view 362 which forms anangle C in range of about 15 degrees to about 50 degrees. In anotherform, angle C is in a range of about 15 degrees to about 35 degrees. Inyet another form, angle C is in a range of about 15 degrees to about 25degrees. Consequently, the overall field of view of reflective elements312 and 314 extends over an angle B, which ranges from about 8 degreesto about 50 degrees in one form, about 10 degrees to about 35 degrees inanother form, and about 12 degrees to about 25 degrees in yet anotherform. Furthermore, field of views 360 and 362 overlap over a rangehaving angle D in a range of about 20 degrees to about 2 degrees, or ina range of about 15 degrees to about 5 degrees. In another form, angle Dis in a range of about 10 degrees to about 8 degrees.

From the foregoing, it can be appreciated that reflective elements 312and 314 provide a wider field of view than a wholly planar rearviewminor element that fully accommodates an equivalent frame having similardimensions. In addition, because reflective elements 312 and 314 haveoverlapping field of views, an image in the field of view of reflectiveelement 314 will transition or move between the reflective elements andappear in both reflective elements during the transition to therebyenable the driver of the automobile to view or be conscious of theobject continuously. In the illustrated embodiment, reflective element314 is positioned in an outboard position relative to reflective element312; therefore, when a vehicle or object that is approaching theautomobile from the rear and to some extent from the side, the image ofthe approaching object will first appear in reflective element 312, thenappear in both reflective elements 314 and 312, and then move toreflective element 314 so that the driver will be initially aware of theapproaching object when its image first appears in reflective element312 and continue to be aware of the object as it moves closer to theautomobile, thus increasing the range of viewing of the driver. Sincethe image transitions smoothly from reflective element 312 to reflectiveelement 314, the driver's awareness of the object is continuous and,further, the driver is not distracted from sudden transitions that oftenoccur with conventional spotter mirrors. Typically, when an object“falls” or “drops” out, a driver's consciousness of the object reducessignificantly, if not ceases, which is one of the causes of manyautomobile blind spot accidents. Hence, when combined with the field ofview of an interior rearview mirror system, the present inventionreduces, if not eliminates, an automobile's blind spot. For furtherdiscussion of blind spots in vehicle rearview mirror systems, referenceis made to U.S. provisional application entitled VEHICULAR REARVIEWMIRROR SYSTEM, Ser. No. 60/252,149, filed Nov. 20, 2000 by Robert E.Schnell, David K. Willmore, and Richard J. Weber, which is incorporatedby reference in its entirety in U.S. Pat. No. 6,717,712 (incorporatedherein above). Thus, the plano-auxiliary reflective element assemblyprovides a seamless rearvision function whereby the image of a sideapproaching/side overtaking other vehicle is substantially seamlesslymaintained as the image of the overtaking or approaching vehicletransitions from being principally and substantially viewed by thedriver of the vehicle (the vehicle mounted with the mirror system of thepresent invention) in the plano reflective element to be seen in theauxiliary reflective element.

Referring to FIG. 23, the numeral 410 generally designates yet anotherembodiment of an automobile exterior sideview mirror system of thepresent invention. Exterior sideview mirror system 410 includes ahousing 412, a first reflective element 414, and a second or auxiliary,separate reflective element 416, which together provide an increasefield of view over conventional planar reflectors mounted in a frame ofequivalent dimensions to the combined lateral dimensions of reflectiveelement 414 and 416.

Housing 412 includes a mirror casing 417 and a sail 418, which mountscasing 412 to a side of an automobile. Though illustrated as a fixedmounting arrangement, it should be understood that minor system 410,like the previous embodiments, may comprise a break-away minor system ora powerfold mirror system.

In the illustrated embodiment, reflective element 414 comprises a planoreflective element having a unit magnification, similar to the planoreflective elements described in reference to the previous embodiments.Reflective element 416 preferably comprises a wide-angle reflector, suchas a convex or aspheric reflector, and may include a multiradiusedcurvature. For further description of suitable reflectors, reference ismade to the previous embodiment.

In the illustrated embodiment, reflective element 416 is mounted in anoutboard position relative to reflective element 414 and is fixedlymounted to bezel 420 of mirror casing 417. In addition, reflectiveelement 416 is preferably angled downwardly and forwardly relative tofirst reflective element 414 when minor system 410 is mounted to anautomobile to thereby increase the field of view of mirror system 410.Optionally and preferably, reflective element 416 is detachably mountedto bezel 420, such as by mechanical fasteners, including clips, so thatreflective element 416 can be removed, such as for replacement.

Reflective element 414 preferably comprises an independentlypositionable reflective element and is mounted by a backing member, suchas a backing plate, to an actuator, which provides multi-axispositioning of reflective element 414. In this manner, reflectiveelement 414 and reflective element 416 are separately and independentlymounted in housing 412. In addition, reflective element 414 optionallyextends behind reflective element 416 in order to maintain the overlapof the field of views of reflective elements 414 and 416 even whenreflective element 414 is moved by the actuator. Similar to the previousembodiment, when an object moves toward the automobile, in which minorsystem 410 is mounted, from the rear of the automobile or laterally withrespect to the automobile, the image of the object will appear initiallyin reflective element 414. As the object moves closer to the automobile,the image of the object will move from reflective element 414 toreflective element 416 such that when the image transitions betweenreflective element 414 and reflective element 416, the image will appearin both reflective elements.

Also, although it is preferable to utilize a multiradius or compoundcurvature reflective element, such as an aspherical element or acompound curvature element, for the second or auxiliary mirror elementadjacent the plano or first reflective element (as this enables leastdiscontinuity in image at the joint between the adjacent elements of theassembly), a spherical reflective element (that has substantially onlyone radius of curvature and, as such, is a section from a sphere) canoptionally be used adjacent the plano reflective element instead of, orin addition to, the multiradius reflective element. Also, a planoauxiliary minor such as a flat mirrored substrate can be used, lesspreferably, as a substitute for a multiradius reflective element inthose embodiments where the auxiliary reflective element is angledrelative to the plane of the principal, plano reflective element so asto view a blind spot region of the principal plano element. Also, theplano-multiradius reflective element assembly can optionally be fixedlyattached to an exterior sideview minor assembly housing that is notmovable, or, alternately, the exterior sideview minor assembly housingto which the plano-multiradius reflective element assembly is fixedlyattached can itself be actuated to move, such as by motor action, sothat by moving the exterior sideview minor assembly housing, the fieldof rearward view of the plano-multiradius reflective element assemblyfixedly attached thereto can correspondingly move and be repositioned tosuit the field of view need of a particular driver seated in theautomobile cabin.

The substrate 18 of the reflective element 12 of the present inventionmay be formed (such as by casting, extrusion or injection molding) of apolymeric optical resin material, such as an acrylic or polycarbonateresin, a polyolefin, a cyclic olefin copolymer, such as a COC resinknown as “TOPAS” and available from Ticona of Summit, N.J. (such as aresin of the type described in U.S. patent application Ser. No.09/946,228, filed Sep. 5, 2001 for IMPROVED PLASTIC SUBSTRATE FORINFORMATION DEVICE AND METHOD FOR MAKING SAME, which is herebyincorporated herein by reference) or the like. Because the substrate canbe, for example, injection molded from an optical resin, the substratemay be molded or formed to a desired shape having a wide angle ormulti-radius surface, which is typically challenging to accomplish withglass sheets. This is because any prescription or form for the substratecan be established in an injection mold by machining, such that when theinjection mold is filled with molten injected optical resin material,the optical resin material takes the shape of the mold. Thus, forexample, a substrate having a substantially or fully flat inboard regionfor a multi-radius (often referred to as an aspheric) exterior minorelement is fully practical.

As shown in FIGS. 1-3, inboard portion or surface 18 c of exteriorsurface 18 b is positioned at or toward the side of the reflectiveelement that is toward the side body of the vehicle when the minorassembly is mounted to or attached to the vehicle. The inboard portion18 c of surface 18 b of substrate 18 may comprise a substantially flator slightly curved or less curved surface, such as a surface having aradius of curvature of preferably greater than at least approximately4000 mm, more preferably greater than at least approximately 9000 mm,and most preferably greater than at least approximately 12000 mm. Theinboard surface 18 c may provide a field of view of up to approximately10 degrees, preferably up to approximately 15 degrees, and morepreferably up to approximately 20 degrees.

Outboard portion or surface 18 d of exterior surface 18 b of substrate18 is positioned outward from inboard portion and is thus further awayfrom the side body of the vehicle when the minor assembly is mounted toor attached to the vehicle. Outboard portion 18 d of exterior surface 18b may be a more convex or curved surface, such that the substratecomprises a wide angle or multi-radius exterior surface substrate. Themore curved outboard surface 18 d of the substrate may have radii ofcurvature in the range of less than about 4000 mm to about 100 mm orlower. The more curved outboard portion or surface 18 d may provide anextended field of view when combined with the less curved inboardportion or surface 18 c. For example, the combined field of view of theminor reflective element 12 may be preferably greater than at leastapproximately 25 degrees, more preferably greater than at leastapproximately 35 degrees, and most preferably greater than at leastapproximately 45 degrees. The substrate may be formed to have curves orshapes or to provide other field of views, without affecting the scopeof the present invention.

The exterior surface 18 b of substrate 18 may be coated or covered witha substantially transparent functional film or layer 20, such as ananti-abrasion film or layer, such as an ultrathin glass film or layer orsheet having a thickness of preferably less than or equal toapproximately 0.8 mm, more preferably less than or equal toapproximately 0.5 mm, and most preferably less than or equal toapproximately 0.3 mm. The ultrathin glass film or layer or sheet 20provides a flexible glass film which can be conformed to the exteriorsurface of the molded substrate (for example, such as described in U.S.Pat. No. 5,085,907, which is hereby incorporated herein by reference)after the substrate is molded. The ultrathin glass film or layer mayprovide substantial protection against scratches on the outboardsurface, such as may occur due to impact by debris at the outside of thevehicle (for exterior minor assembly applications) or by use of icescrapers and the like on the glass surface and the like. The ultrathinglass film or layer may be applied to a molded or extruded strip (suchas described below with respect to FIGS. 5-8) or may be applied to thesurface or surfaces of a formed or cut substrate, without affecting thescope of the present invention. The flexible ultrathin glass film orlayer of the present invention allows the wide angle or multi-radiussubstrate to be molded in the desired shape out of a transparent acrylicresin material, yet may conform to the curved or multi-radius oraspheric shape and provide enhanced protection or scratch resistance tothe substrate.

It is envisioned that other functional films or hard coats oranti-abrasion films or the like may be applied to the exterior surfaceof the molded substrate, such as via adhering or applying a film to theexterior surface or via dip coating or vacuum deposition or the like.Optionally, a hydrophobic film or hydrophilic film or element orproperty may also or otherwise be applied to the exterior surface 18 bof the substrate. Optionally, the functional film may comprise anon-glass or polymeric film, such as a polymeric material that is aharder and/or different property material than the substrate itself.Optionally, the anti-abrasion film may be formed of the same resinmaterial as the substrate to match the coefficients of thermal expansionand thus reduce thermal expansion/contraction mismatches between thematerials.

Optionally, the inner or rear surface 18 a of the substrate 18 may havea reflective layer or coating or film or sheet 22 laminated or otherwiseapplied thereto. For example, the reflective layer or film 22 maycomprise a polymeric reflective film 22 laminated or otherwise adheredor applied to the rear or inner surface 18 a of a molded or extruded orcast strip (such as described below with respect to FIGS. 5-8) or of themolded or formed substrate 18. Reflective film 22 may comprise apolymeric reflective film, such as an all polymer-thin-film multilayer,high reflective minor film, such as a multilayer, non-metallicreflective film which may comprise multiple coextrusion of many plasticlayers to form a highly reflective mirror film, such as described inU.S. Pat. Nos. 3,773,882; 3,884,606; and 3,759,647, which are herebyincorporated herein by reference. Such a reflective film thus maycomprise multilayers of polymer materials to form a highly reflectiveminor film, such as a Radiant Light Film, a Radiant Mirror Film or aRadiant Color Film, such as commercially available from 3M of St. Paul,Minn., such as a Radiant Color Film CM590 or CM500. Also, a durablemetallized polymeric minor layer can be used, such as described in U.S.Pat. No. 5,361,172, which is hereby incorporated herein by reference.

As shown in FIG. 4, it is envisioned that a substrate or substrate shapeor sheet or strip of substrate material 118 may have a reflective filmor layer 122 adhered or laminated or otherwise applied to the exteriorsurface 118 b of the substrate material. An anti-abrasion film or layer120 (which may comprise an ultrathin glass film or layer as describedabove) may be adhered or laminated or otherwise applied to thereflective film or layer 122. In such an application, with thereflective layer on the front or exterior surface of the substrate, thesubstrate material may be molded or formed of a polymeric material thatdoes not provide optical clarity and need not be transparent. Thesubstrate material may act only as a support or backing plate for thereflective film or layer and the anti-abrasion film or layer and thusmay be opaque or non-transparent. The exterior surface 118 b ofsubstrate material 118 may comprise a wide angle exterior surface or amulti-radius exterior surface having a less curved inboard portion orsurface 118 c and a more curved outboard portion or surface 118 d, suchas discussed above with respect to substrate 18.

Optionally, and such as shown in FIGS. 5, 6 and 8, the optical resinmaterial may be molded or extruded or cast into a generally continuousstrip 19 having the desired curved or multi-radius surfaces, and may becut to form the substrates. The substrates may be cut from the strip viaany known cutting process, such as via a laser cutting process or awater-jet cutting process or the like, without affecting the scope ofthe present invention.

As shown in FIGS. 5-8, the molding processes and film or layerapplication processes of the present invention may be used to form aprismatic or wedge-shaped strip for forming prismatic or wedge-shapedsubstrates 18′ (FIG. 7) for use in an interior rearview mirror assemblyof a vehicle.

As also shown in FIGS. 5-8, the substrate material or optical resinmaterial may be extruded or cast to form the continuous strip or sheet19. For example, and as shown in FIGS. 5 and 5A, the strip 19 may beextruded by an extruder 24, which, preferably continuously, extrudes theoptical resin material through an extrusion nozzle 26. The extrudedmaterial may be moved through an annealing lehr 28 to reduce orsubstantially eliminate birefringence, striation, stress and/ordistortion in the strip or substrates. The coatings or layers or films20 and/or 22 may be applied to one or both surfaces of the strip orsubstrate after the annealing process. The strip 19 may then be cut,such as via laser cutting or water-jet cutting devices or processes 30,or via other forming processes, to form the substrates 18′ after thefilms or coatings have been applied thereto.

Optionally, and as shown in FIG. 8, the strip 19 of optical polymericresin material may be cast by a caster 32, which deposits the moltenpolymer or resin material onto a float section 34, such as a heatedplate or heated melt. The float section 34 may be angled to form thewedge-shaped strip as the strip or ribbon of cast molten polymersolidifies as it passes across the hot float section (it is alsoenvisioned that the float may provide a curved surface to form thecurved outboard surface of the substrate). The coatings or layers orfilms 20, 22 may be applied to the solidified strip and the strip may becut to form the substrates after the coatings or layers or films havebeen applied thereto.

Because the films or layers are flexible, it is envisioned that theanti-abrasion film or ultrathin glass film and/or the reflectivepolymeric film may be unwound or unrolled and applied along thegenerally continuously extruded or cast substrate material or strip 19.For example, and as shown in FIGS. 5-8, the ultrathin glass film (orother outer layer anti-abrasion coating or film) 20 may be provided in areel or roll form or strip 20 a and may be unwound or unrolled andlaminated or otherwise adhered or applied along the exterior surface 19b of the extruded or cast strip 19 of substrate material. Likewise, thereflective polymeric film 22 may be provided in a reel or roll form orstrip 22 a and may be attached or applied to the inner surface 19 a ofthe substrate material strip 19, such as via laminating or adhering orotherwise applying the film to the substrate material, such as by usingoptical adhesive and/or via rolling or ironing the film or sheet(preferably at an elevated temperature and with vacuum assist) onto thesubstrate or strip surface, to secure the reflective film to thesubstrate or extruded or cast strip or sheet.

Optionally, the glass film or layer or sheet (or reel or roll of glasssheet or strip) may be coated with a highly reflective metallic layer,such as silver or aluminum or the like, deposited on or applied to itsinner surface (i.e., the surface which is adhered to or otherwiseapplied to the substrate or substrate sheet or strip). The reflectivelayer or coating may be applied to the glass film or layer with orwithout transparent overcoats. The glass film thus may provide thereflective layer at the exterior surface of the substrate, such that thereflective layer provides the second layer or surface, with thesubstrate behind the reflective layer. The glass sheet or film may thusbe provided with the reflective minor coating already applied thereto.The glass layer with reflective layer or coating applied thereto may beprovided in a reel or roll form for applying both the reflective layerand the anti-abrasion layer to the exterior surface of the substrate orsubstrate strip or sheet in one application process. In such anapplication, the substrate material need not comprise a transparentoptical resin material, and a separate reflective layer or film orcoating would not be necessary at the inner or rear surface of thesubstrate.

It is envisioned that other hard coats or films or the like may beapplied to one or more surfaces of the molded substrate strip or to themolded and cut substrates, such as via dip coating or vacuum depositionor the like, without affecting the scope of the present invention. Theother hard coats or films may be substantially flexible and may beapplied via unrolling of a reel of an anti-abrasion film or sheet andapplying the film or sheet to a surface of an extruded or cast strip oftransparent acrylic resin or the like, as discussed above. Optionally, ahydrophobic film or hydrophilic film or element or property may also orotherwise be applied to (or sprayed on) one or both surfaces 18 a, 18 bof the substrate or strip or sheet. Optionally, one or both of thereflective polymeric film 22 and the anti-abrasion film 20 may be formedof the same resin material as the substrate 18, 18′ or substrate strip19 to match the coefficients of thermal expansion and thus reducethermal expansion/contraction mismatches between the materials.

Optionally, it is envisioned that such ultrathin glass films,anti-abrasion films, reflective films or reflective systems may be usedfor electrochromic mirror reflective elements or cells as well. Forexample, the interior or exterior rearview mirror assembly of thepresent invention may comprise an electrochromic minor, such as anelectrochromic minor assembly and electrochromic element utilizingprinciples disclosed in commonly assigned U.S. Pat. Nos. 5,140,455;5,151,816; 6,690,268; 6,178,034; 6,154,306; 6,002,544; 5,567,360;5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012;5,117,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407 and/or 4,712,879,which are hereby incorporated herein by reference, and/or as disclosedin the following publications: N. R. Lynam, “Electrochromic AutomotiveDay/Night Minors”, SAE Technical Paper Series 870636 (1987); N. R.Lynam, “Smart Windows for Automobiles”, SAE Technical Paper Series900419 (1990); N. R. Lynam and A. Agrawal, “Automotive Applications ofChromogenic Materials”, Large Area Chromogenics: Materials and Devicesfor Transmittance Control, C. M. Lampert and C. G. Granquist, EDS.,Optical Engineering Press, Wash. (1990), which are hereby incorporatedby reference herein. The mirror assembly may comprise an interiorrearview mirror assembly, and may include an accessory module or may bemounted to an accessory module, such as an accessory module of the typesdisclosed in U.S. patent application Ser. No. 10/355,454, filed Jan. 31,2003 for VEHICLE ACCESSORY MODULE, now U.S. Pat. No. 6,824,281, which ishereby incorporated herein by reference.

Optionally, the minor assembly may include one or more displays fordisplaying information to a driver of the vehicle at or through thereflective element of the mirror assembly. For example, the mirrorassembly may include one or more displays of the types described in U.S.Pat. Nos. 6,329,925; 6,501,387; 6,690,268; 5,910,854; 6,420,036;5,668,663; and 5,724,187, and/or in U.S. patent application Ser. No.10/054,633, filed Jan. 22, 2002 by Lynam et al. for VEHICULAR LIGHTINGSYSTEM, now U.S. Pat. No. 7,195,381; and Ser. No. 10/456,599, filed Jun.6, 2003 by Weller et al. for INTERIOR REARVIEW MIRROR SYSTEM WITHCOMPASS, now U.S. Pat. No. 7,004,593, and/or in PCT Application No.PCT/US03/29776, filed Sep. 19, 2003 by Donnelly Corporation et al. forELECTROCHROMIC MIRROR ASSEMBLY; PCT Application No. PCT/US03/35381,filed Nov. 5, 2003 by Donnelly Corporation et al. for ELECTRO-OPTICREFLECTIVE ELEMENT ASSEMBLY; and/or PCT Application No. PCT/US03/40611,filed Dec. 19, 2003 by Donnelly Corporation et al. for ACCESSORY SYSTEMFOR VEHICLE, and/or in U.S. provisional applications, Ser. No.60/508,086, filed Oct. 2, 2003 by Schofield for MIRROR REFLECTIVEELEMENT ASSEMBLY INCLUDING ELECTRONIC COMPONENT; Ser. No. 60/525,952,filed Nov. 26, 2003 by Lynam for MIRROR REFLECTIVE ELEMENT FOR AVEHICLE; Ser. No. 60/471,546, filed May 19, 2003; Ser. No. 60/525,537,filed Nov. 26, 2003; and Ser. No. 60/556,259, filed Mar. 25, 2004, whichare all hereby incorporated herein by reference, without affecting thescope of the present invention.

Optionally, the minor assembly may include or be associated withelectronic accessories, such as, for example, antennas, including globalpositioning system (GPS) or cellular phone antennas, such as disclosedin U.S. Pat. No. 5,971,552, a communication module, such as disclosed inU.S. Pat. No. 5,798,688, a blind spot detection system, such asdisclosed in U.S. Pat. Nos. 5,929,786 and/or 5,786,772, a high/lowheadlamp controller, such as disclosed in U.S. Pat. Nos. 5,796,094and/or 5,715,093, transmitters and/or receivers, such as a garage dooropener or the like, a digital network, such as described in U.S. Pat.No. 5,798,575, a memory minor system, such as disclosed in U.S. Pat. No.5,796,176, a hands-free phone attachment, a video device for internalcabin surveillance and/or video telephone function, such as disclosed inU.S. Pat. Nos. 5,760,962 and/or 5,877,897, a remote keyless entryreceiver or system or circuitry and/or a universal garage door openingsystem or circuitry (such as the types disclosed in U.S. Pat. Nos.6,396,408; 6,362,771; 5,798,688 and 5,479,155, and/or U.S. patentapplication Ser. No. 10/770,736, filed Feb. 3, 2004 by Baumgardner etal. for GARAGE DOOR OPENING SYSTEM FOR VEHICLE, now U.S. Pat. No.7,023,322), lights, such as map reading lights or one or more otherlights or illumination sources, such as disclosed in U.S. Pat. Nos.6,690,268; 5,938,321; 5,813,745; 5,820,245; 5,673,994; 5,649,756;5,178,448; 5,671,996; 4,646,210; 4,733,336; 4,807,096; 6,042,253; and/or5,669,698, and/or U.S. patent application Ser. No. 10/054,633, filedJan. 22, 2002 by Lynam et al. for VEHICULAR LIGHTING SYSTEM, now U.S.Pat. No. 7,195,381, microphones, such as disclosed in U.S. Pat. Nos.6,243,003; 6,278,377; and/or 6,420,975, and/or PCT Application No.PCT/US03/30877, filed Oct. 1, 2003, speakers, a compass or compasssystem, such as disclosed in U.S. Pat. Nos. 5,924,212; 4,862,594;4,937,945; 5,131,154; 5,255,442; and/or 5,632,092, and/or U.S. patentapplication Ser. No. 10/456,599, filed Jun. 6, 2003 by Weller et al. forINTERIOR REARVIEW MIRROR SYSTEM WITH COMPASS, now U.S. Pat. No.7,004,593, a navigation system, such as described in U.S. Pat. No.6,477,464, and U.S. patent application Ser. No. 10/456,599, filed Jun.6, 2003 by Weller et al. for INTERIOR REARVIEW MIRROR SYSTEM WITHCOMPASS, now U.S. Pat. No. 7,004,593; Ser. No. 10/287,178, filed Nov. 4,2002 by McCarthy et al. for NAVIGATION SYSTEM FOR A VEHICLE, now U.S.Pat. No. 6,678,614; Ser. No. 10/645,762, filed Aug. 20, 2003 by Tayloret al. for VEHICLE NAVIGATION SYSTEM FOR USE WITH A TELEMATICS SYSTEM,now U.S. Pat. No. 7,167,796; and Ser. No. 10/422,378, filed Apr. 24,2003, now U.S. Pat. No. 6,946,978; and/or PCT Application No.PCT/US03/40611, filed Dec. 19, 2003 by Donnelly Corporation et al. forACCESSORY SYSTEM FOR VEHICLE, a tire pressure monitoring system, such asthe types disclosed in U.S. Pat. Nos. 6,294,989; 6,445,287; and/or6,472,979, and/or in U.S. patent application Ser. No. 10/206,495, filedJul. 26, 2002 by Schofield et al. for SELF TRAINING TIRE PRESSUREMONITORING SYSTEM, now U.S. Pat. No. 6,731,205, a seat occupancydetector, a trip computer, a telematics system, such as an ONSTAR®system or the like, and/or any other desired accessory or system or thelike (with all of the above-referenced patents and patent applicationsand PCT applications being commonly assigned to Donnelly Corporation,and with the disclosures of all of the above referenced patents andpatent applications and PCT applications being hereby incorporatedherein by reference in their entireties).

Optionally, a vehicle compass or compass system may comprise a printedcircuit board and may be positioned within a pod or the like that may befixedly mounted in the vehicle. The compass may be initially calibrated(such as at the assembly plant or the like) via a small Helmholtz coilthat may accommodate the small circuit board or pod. The coil induces afield to calibrate the compass, such as described in U.S. provisionalapplication Ser. No. 60/467,899, filed May 5, 2003, which is herebyincorporated herein by reference in its entirety. The induced field inthe miniature Helmholtz coil may be controlled via the use of a highlypermeable magnetic shielding material that may enclose the miniatureHelmholtz coil with only a small slot for the circuit board or compasspod to enter through. Such a set up may allow the compass podmanufacturer to automate and magnetically shield the calibration andtest stage of a microprocessor-based compass. The calibration processmay utilize an indexing rotary table that may rotate to move a compasspod from a loading bay to a calibration bay. The shielded Helmholtz coilmay be adjacent to the rotary table and may be shuttled back and forthto align with the rotary table to receive a compass pod therefrom. Therotary table may rotate to move a calibrated compass pod (after itleaves the miniature Helmholtz coil) from the calibration bay to a finalfunctional test station to test the calibrated compass pod.

Therefore, the present invention provides a wide angle or multi-radiussingle substrate or reflective element which may provide an enhancedfield of view for an interior or exterior rearview minor assembly. Thewide angle or multi-radius single element reflector may have ananti-abrasion coating or ultrathin glass film conformed to and appliedto the exterior curved surface of the substrate. The substrate may bemolded or extruded into the desired shape and may be formed into anelongated strip or sheet, whereby the anti-abrasion coating or film maybe applied along the strip before the strip is cut into the desiredsubstrates. The present invention thus provides a single element wideangle or multi-radius substrate which has enhanced scratch resistance. Apolymeric reflective film may be laminated, adhered or otherwise appliedto the opposite inner surface of the substrate or extruded strip whilethe anti-abrasion coating or film is applied to the exterior surface.Optionally, a reflective film or layer may be applied to the exteriorsurface of the substrate and an anti-abrasion film or layer may beapplied to the reflective film or layer.

Changes and modifications in the specifically described embodiments canbe carried out without departing from the principles of the presentinvention, which is intended to be limited only by the scope of theappended claims, as interpreted according to the principles of patentlaw.

1. An exterior rearview mirror assembly for a motor vehicle, saidexterior rearview minor assembly comprising: a bracket fixedly securedto the motor vehicle; a mirror casing secured to said bracket, saidminor casing defining a primary opening; a primary minor disposed withinsaid primary opening for providing a view rearward of the motor vehiclethrough a primary field of view, said primary mirror defining a primaryplane; a spotting minor spaced apart from said primary mirror, saidspotting minor extending through a secondary plane different from saidprimary plane; and a divider extending between said primary mirror andsaid spotting mirror to separate said primary and secondary mirrorsvisually.
 2. An exterior rearview mirror assembly as set forth in claim1 wherein said spotting mirror is forward of said primary plane.
 3. Anexterior rearview mirror assembly as set forth in claim 1 wherein saidspotting mirror is rearward of said primary plane.
 4. An exteriorrearview mirror assembly for a motor vehicle, said exterior rearviewminor assembly comprising: a bracket fixedly secured to the motorvehicle; a mirror casing secured to said bracket, said minor casingdefining a primary opening; a primary minor disposed within said primaryopening for providing a view rearward of the motor vehicle through aprimary field of view, said primary mirror defining a primary plane; aspotting minor spaced apart from said primary mirror, said spottingminor extending through a secondary plane different from said primaryplane; a divider extending between said primary mirror and said spottingmirror to separate said primary and secondary mirrors visually; andwherein said primary mirror comprises one of (a) a generally flat glasssubstrate having a surface coated with a metallic reflector coating and(b) a generally flat polymeric substrate having a thin glass elementapplied to a surface thereof and with an opposing surface thereof havinga reflecting layer applied thereto.
 5. An exterior rearview mirrorassembly as set forth in claim 4 wherein said spotting mirror is forwardof said primary plane.
 6. An exterior rearview mirror assembly as setforth in claim 4 wherein said spotting mirror is rearward of saidprimary plane.
 7. An exterior rearview mirror assembly for a motorvehicle, said exterior rearview minor assembly comprising: a bracketfixedly secured to the motor vehicle; a mirror casing secured to saidbracket, said minor casing defining a primary opening; a primary minordisposed within said primary opening for providing a view rearward ofthe motor vehicle through a primary field of view, said primary mirrordefining a primary plane; a spotting minor spaced apart from saidprimary minor, said spotting minor extending through a secondary planedifferent from said primary plane; wherein said spotting mirror is at anangle relative to said primary mirror; a divider extending between saidprimary mirror and said spotting mirror to separate said primary andsecondary mirrors visually; and wherein said primary mirror comprisesone of (a) a generally flat glass substrate having a surface coated witha metallic reflector coating and (b) a generally flat polymericsubstrate having a thin glass element applied to a surface thereof andwith an opposing surface thereof having a reflecting layer appliedthereto.
 8. An exterior rearview mirror assembly as set forth in claim 7wherein said spotting mirror is forward of said primary plane.
 9. Anexterior rearview mirror assembly as set forth in claim 7 wherein saidspotting mirror is rearward of said primary plane.
 10. An exteriorrearview mirror assembly as set forth in claim 7, wherein the secondfield of view of said spotting mirror is generally directed at least oneof outwardly and downwardly with respect to the longitudinal axis of themotor vehicle when said exterior rearview minor assembly is attached tothe motor vehicle.
 11. An exterior rearview mirror assembly as set forthin claim 7, wherein said spotting minor is at an angle of at least aboutthree degrees relative to said primary mirror.